Tunable impedance load-bearing structures

ABSTRACT

A tunable impedance load bearing structure includes a support comprising an active material configured for supporting a load, wherein the active material undergoes a change in a property upon exposure to an activating condition, wherein the change in the property is effective to change an impedance characteristic of the support.

BACKGROUND

The present disclosure generally relates to tunable impedance loadbearing structures, and more particularly, to active material basedtunable impedance load bearing structures.

Load bearing structures such as beams, columns, rails, cables, panels,brackets, and the like are typically designed to withstand variousstatic and dynamic external and internal forces and moments whilemaintaining their shape and position within acceptable deformationtolerances. A critical characteristic of these structural applicationsis stiffness. Currently, stiffness characteristics of a given loadbearing structure can be improved by optimizing structure geometryand/or materials to suit certain loading conditions (e.g., foam fillinghollow cross sections of a load bearing structure). For dynamicapplications, the damping characteristics of the material may play amore critical role. In the case of a load bearing structure which isexperiencing vibratory excitation, the damping properties of thestructure may be optimized so that its performance excels when excitedat a single frequency. The improved performance of these structures,however, is designed around a specific set of loading conditions. Assuch, the structure may not perform as desired under loading conditionsoutside the set of specific conditions focused on during design andfabrication of the structure.

Moreover, the specific characteristics desired at the time ofmanufacture and/or installation of the load bearing structure mayactually be detrimental in certain situations, i.e., under circumstanceswhere dramatically different load bearing characteristics would beadvantageous. One example of such a situation, not intended to belimiting, could be in the automotive industry, where load bearingstructures are designed to perform in a relatively rigid manner duringnormal operation, but during extraordinary circumstances, such as in animpact event, a drastically more compliant or a drastically stifferstructure may be preferable. Prior art load bearing structures areunable to make such significant changes in characteristics, rather thesestructures simply provide a fixed response, which is inherent to thecharacteristics contemplated at the time of design. In other words,current load bearing structures are not tunable.

Accordingly, there is a need for an improved load bearing structure. Itwould be desirable for such an improved load bearing structure toexhibit tunable impedance characteristics, i.e., be able to variouslychange structural and or material characteristics to meet changing loadrequirements in order to improve performance across a wider range ofservice conditions.

BRIEF SUMMARY

Disclosed herein are tunable impedance load bearing structurescomprising an active material. In one embodiment, a tunable impedanceload bearing structure includes a support comprising an active materialconfigured for supporting a load, wherein the active material undergoesa change in a property upon exposure to an activating condition, whereinthe change in the property is effective to change an impedancecharacteristic of the support.

In another embodiment, a tunable impedance load bearing structureincludes a support configured for supporting a load including, an upperportion having a first flat surface and a second flat surface, wherein acanted beam element is disposed between the first flat surface and thesecond flat surface, a first disc comprising an active material inphysical communication with the second flat surface of the upperportion, wherein the active material undergoes a change in a propertyupon exposure to an activating condition, wherein the change in theproperty is effective to change a compliance characteristic of thesupport, and a second disc in physical communication with the firstdisc.

A method for changing an impedance characteristic of a load bearingstructure includes, disposing a load bearing structure intermediate asubstrate and a load, wherein the load bearing structure comprises asupport configured for supporting the load, wherein the supportcomprises an active material, and activating the active material toeffect a change in a property of the active material, wherein the changein the property is effective to change an impedance characteristic ofthe load bearing structure.

The disclosure may be understood more readily by reference to thefollowing detailed description of the various features of the disclosureand the examples included therein.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the figures wherein the like elements are numberedalike:

FIG. 1 is an illustration of a perspective view of one embodiment of atunable impedance load bearing structure showing (a) a load bearingstructure in a default state, and (b) an activated load bearingstructure;

FIG. 2 is an illustration of a perspective view of one embodiment of atunable impedance load bearing structure showing (a) a load bearingstructure in a default state, and (b) a load bearing structure in anactivated state;

FIG. 3 is an illustration of a perspective view of one embodiment of atunable impedance load bearing structure showing (a) a load bearingstructure in a default state, and (b) an activated load bearingstructure; and

FIG. 4 is an illustration of a perspective view of one embodiment of atunable impedance load bearing structure showing (a) a load bearingstructure in a default state, and (b) an activated load bearingstructure.

DETAILED DESCRIPTION

Active material based tunable impedance load bearing structures andmethods of using tunable impedance load bearing structures are disclosedherein. In contrast to prior art load bearing structures, the tunableimpedance load bearing structures disclosed herein have portions formedof, or are fabricated entirely from, active materials. The disclosedtunable impedance load bearing structures advantageously use activematerials to variously change an impedance characteristic of the supportstructure, e.g., a compliance or damping property change. The ability tovariously change impedance characteristics greatly increases thefunctionality of the disclosed load bearing structures by improving thecapability to meet the demands of different loading conditions and/orsituations. As used herein, the term “load bearing structures” isintended to include without limitation, beams, columns, rails, cables,panels, brackets, connectors, mounts, spacers, grommets, and the like,which could be employed to provide support to an external or internalload. The term “active material” as used herein generally refers to amaterial that exhibits a change in a property such as, withoutlimitation, a change in an elastic modulus, a shape, a dimension, aphase change, a component location, or a shape orientation upon exposureto an activating condition. Suitable active materials include, withoutlimitation, shape memory alloys (“SMAs”; e.g., thermal and stressactivated shape memory alloys and magnetic shape memory alloys (MSMA)),electroactive polymers (EAPs) such as dielectric elastomers, ionicpolymer metal composites (IPMC), piezoelectric materials (e.g.,polymers, ceramics), and shape memory polymers (SMPs), shape memoryceramics (SMCs), baroplastics, magnetorheological (MR) materials (e.g.,fluids and elastomers), electrorheological (ER) materials (e.g., fluids,and elastomers), composites of the foregoing active materials withnon-active materials, systems comprising at least one of the foregoingactive materials, and combinations comprising at least one of theforegoing active materials. Depending on the particular active material,the activating condition can take the form of an activation signal,which can be, without limitation, an electric current, a temperaturechange, a magnetic field, a chemical activation signal, a mechanicalloading or stressing, and the like.

Also, the terms “first”, “second”, and the like do not denote any orderor importance, but rather are used to distinguish one element fromanother, and the terms “the”, “a”, and “an” do not denote a limitationof quantity, but rater denote the presence of at least one of thereferenced item. Furthermore, all ranges directed to the same quantityof a given component or measurement is inclusive of the endpoints andindependently combinable.

Turning now to FIG. 1, an exemplary embodiment of a tunable impedanceload bearing structure 10 is illustrated. In this embodiment, a support12 takes the form of a cantilever beam, but it is to be understood thatthe structure may take any form suitable for supporting a load, such asthose described above. Also in this embodiment, the entire support,i.e., the cantilever beam 12 is formed of an active material, e.g., aSMP. The cantilever beam 12 is in physical communication with asubstrate 14. A force 16, such as an external load, is in physicalcommunication with a free end of the cantilever beam 12.

In operation, the cantilever beam 12 displaces a distance Δ_(a) whensubjected to the tip force 16, as shown in FIG. 1( a). When the activematerial of the cantilever beam 12 is exposed to an activatingcondition, the cantilever beam 12 displaces a distance Δ_(b) whensubjected to the same tip force 16, as shown in FIG. 1( b). When theactive material is activated, the material undergoes a change in aproperty, e.g., an elastic modulus. In this case, the modulus of theactive material is lowered; therefore, as can be seen in FIG. 1, thedisplacement distance Δ_(b) is greater than the distance Δ_(a) when thesame force 16 is applied. Conversely, a much smaller tip force would berequired to displace the cantilever beam 12 a distance Δ_(a) when theactive material is exposed to an activating condition. An optionalactivation device 18 is in operative communication with the load bearingstructure 10 and is configured to selectively provide the activationsignal to the active material.

FIG. 2 depicts another exemplary embodiment of a tunable impedance loadbearing structure 50. The support 52 again takes the form of acantilever beam without limitation. In this embodiment, however, thesupport 52 has a section, e.g., a joint 54, formed of active material,rather than the entire support. The cantilever beam 52, therefore, hasthree sections. A first portion 56 is in physical communication with asubstrate 14 and the active material joint 54, making up the secondportion. A third portion 58 forms the end of the cantilever beam 52 andis in physical communication with the active material joint 54. A force60, such as an external load, is in physical communication with the freeend of the second portion 58 of the cantilever beam 52.

In operation, the cantilever beam 52 displaces a distance Δ_(a) whensubjected to the tip force 60, as shown in FIG. 2( a). In this state,i.e., where the active material is not activated, the cantilever beam 52deflects in the same manner as a homogenous beam. The deformation isdistributed along the entire length of the beam 52 to displace adistance Δ_(a). When the active material of the joint 54 is exposed toan activating condition, the cantilever beam 52 displaces a distanceΔ_(b) when subjected to the same force 60, as shown in FIG. 2( b). Whenexposed to the activating condition, the material undergoes a change ina property, e.g., an elastic modulus. In this case, the modulus of theactive material joint 54 is lowered to a value below that of the firstand third portions 56, 58; therefore, as can be seen in FIG. 2( b), thejoint 54 deforms locally. The local deformation of the active materialjoint 54 produces a much larger beam deflection than without the activematerial activated, and almost no deformation of the inactive firstportion 56 and third portion 58 occurs as a result.

Both the tunable impedance load bearing structures of FIG. 1 and FIG. 2are embodiments which have active materials located at strategic pointswithin the load bearing structure to control how and where the structurewill deform. Turning now to FIG. 3, another exemplary embodiment of atunable impedance load bearing structure 100 is illustrated, where thechange in a property of an active material controls the degree and/ordirection of deformation. In this embodiment the support 102 takes theform of a variably complaint column. The column 102 includes an upperportion 110 having a first flat surface 112 and a second flat surface114. Canted beams 116 are disposed between the first flat surface 112and the second flat surface 114. A first disc 118 is formed of an activematerial and is in physical communication with the second flat surface114 and a second disc 120. The second disc 120 is fixed to a substrate14. A force 122, such as an external compressive load, is in physicalcommunication with the upper portion 110 of the tunable impedance column102.

In operation, the column 102 displaces a distance Δ_(a) when subjectedto the compressive force 122, as shown in FIG. 3( a). In this state,i.e., where the active material is not activated, there are negligibledeformations within flat surfaces 112 and 115 and the discs 118 and 120.The canted beams 116 bend into an “S” shape. In this deactivated state,the modulus of the column gives the structure stiffness capable ofwithstanding the force 122. When the active material of the first disc118 is exposed to an activating condition, the column 100 displaces adistance Δ_(b) when subjected to the same force 122, as shown in FIG. 3(b). When exposed to the activating condition, the material undergoes achange in a property, e.g., an elastic modulus. The modulus of theactive material first disc 118 is lowered to a value below that of theother column components. When the compressive force 122 is applied tothe column 100 in this activated state, the deformation is torsional.The activated first disc 118 allows the second flat surface 114 torotate relative to the first flat surface 112, resulting in the cantedbeams 116 collapsing on top of one another. Such deformation directionlowers the overall stiffness of the column 102 and results in adisplacement Δ_(b) greater than that of Δ_(a).

In FIG. 4, yet another exemplary embodiment of a tunable impedance loadbearing structure 150 is illustrated. In this embodiment, a change in aproperty of an active material is capable of altering the load pathwithin the load bearing structure. The support 151 is composed of a flatmember 152 fixed to a substrate 14 and in physical communication with anangled member 154. Both members may be formed of an inactive material,such as steel. At one end the flat member 152 and the angled member 154are rigidly joined. The two members may be joined by a weld, adhesive,bolt, pin, and the like. At the free end of the members 152 and 154, apin 156 formed of active material is disposed in a first aperture 153 ofthe flat member 152 and a second aperture 155 of the angled member 154.The pin 156 is in operative communication with flat member 152 and theangled member 154. A force 158, such as an external load, is in physicalcommunication with the support 151.

In operation, the load bearing structure 150 displaces a distance Δ_(a)when subjected to the force 158, as shown in FIG. 4( a). When the activematerial pin 156 is in a deactivated state, it has a strength capable ofwithstanding the force 158 and holding the connection between the flatmember 152 and the angled member 154. In this state, a only a smallamount of deflection, Δ_(a), occurs to angled member 154 as most of theforce is supported by the upper flat member 152. When the activematerial of the pin 156 is exposed to an activating condition, thestrength of the pin 156 drastically drops, allowing the same force 122to elicit failure of the pin 156. As a result of the failure, the loadpath of the structure 150 is rerouted through the lower angled member154, which deflects a distance Δ_(b), substantially greater than Δ_(a),as shown in FIG. 3( b). To reiterate, in this embodiment, the activematerial component of the load bearing structure is situated to alterthe load path within the structure upon exposure to an activatingcondition. Similarly, an in-active pin could be actuated using an activematerial, leading to the same change in the structure's load path.

As used above, the distances “Δ_(a)” and “Δ_(b)” are utilized to showthe difference between the deflection distance of a tunable impedanceload bearing structure in a deactivated state and a deflection distancein an activated state. The labels “Δ_(a)” and “Δ_(b)” are merely usedfor each figure as a matter of convenience and are not intended torepresent equal deflection distances for each separate embodiment of thetunable impedance load bearing structure. Moreover, the tunableimpedance load bearing structures disclosed above are mere exemplaryembodiments of possible load bearing structures and are not intended tobe limited to the above disclosed designs. The tunable impedance loadbearing structures can be configured in any suitable shape. Also, theload bearing structures can have a single active material component orcan have multiple active material components, with each active materialcomponent configured to alter a stiffness, create a crush initiationsite, change a degree, direction, or preferred mode of deformation,alter a load path within the structure, any combination of theforegoing, and the like, of a tunable impedance load bearing structure.The ability of the active material based load bearing structures toadapt and comply to changing loads and situations can be beneficial inmany applications, such as, without limitation, automotive, aerospace,static structure, and the like.

In yet another mode of operation, the above disclosed tunable impedanceload bearing structures can also provide alignment and lockingcapabilities, useful in applications such as a vehicle manufacturing andassembly processes. The active material based tunable impedance loadbearing structure can be activated during the vehicle assembly process,thereby lowering the modulus, for example, and permitting a vehicle bodypanel, supported by the load bearing structure, to be positioned/alignedrelative to a vehicle frame. While in this newly aligned position,cooling the active material of the load bearing structure will cause theactive material to stiffen, locking the load bearing structure in thenewly aligned position and providing a path to transfer static loadon/from the fender to the vehicle frame. Such capability allows thevehicle body to be reversibly realigned throughout the vehicle's life.

When active material of a load bearing structure is exposed to anactivating condition, the active material undergoes a change in aproperty. The changed property can be, without limitation, a shapechange, a shape orientation change, a phase change, a change in modulus,a change in strength, a change in dimension, or any combination of theforegoing. The resultant change in property of the active materialproduces a change in an impedance characteristic of the load bearingstructure. Such a change in a compliance characteristic can be, withoutlimitation, a stiffness change, a damping capability change, a yieldstrength change, a change in force-deflection behavior, a change inload-carrying capacity, a change in energy absorption capacity, anycombination of the foregoing, and the like.

Exposing the active material to an activating condition can be done invarious ways. An activation device can be used to transmit an activationsignal, e.g., a thermal signal, to the active material. The activationdevice may incorporate sensors which could trigger the activatingcondition in response to a predetermined event, current or anticipatedchanges in the operating environment, or allow direct activation of thematerial though user input. Such an active system could also provide theoption of a feedback loop where monitoring the degree of materialtransformation, geometrical change, and structure integrity of the loadbearing structure is possible. Another option could be to have a passiveactivation system where the active material component of a load bearingstructure can be activated by external environmental conditions, e.g. alocal temperature change. Another embodiment could include both apassive and active activation system. One example could allow certainactive material elements of the structure to be activated passively andother elements to be activated via an activation device. Another exampleusing both passive and active systems could include a passive system toprecondition an active material element and an active system to fullyactivate the active material. As used herein, the term “precondition”generally refers to minimizing the energy required to effectdeformation. Using SMP as an example for ease in discussion, the SMP canbe maintained at a preconditioning temperature just below the glasstransition temperature. In this manner, the activation signal, e.g., athermal activation signal, requires minimal energy to effect thermaltransformation since the transformation temperature is only slightlygreater than the preconditioning temperature. As such, preconditioningminimizes the amount of additional beating and time necessary to causetransformation of the SMP, thereby providing a rapid response on theorder of a few milliseconds, if desired. In a preferred embodiment, thepreconditioning does not cause any transformation of the SMP, unlessintentionally designed.

As indicated, the change of impedance characteristics in a tunableimpedance load bearing structure occurs through exposure of an activematerial to an activating condition. For example, in the case of a loadbearing structure having a SMP component, a thermal activation signal isrequired to change the temperature of the SMP. In order to produce therequired temperature change, the SMP can be resistively heated,radiatively heated, and/or conductively heated using such means thatinclude, but are not intended to be limited to, conduction from a higheror a lower temperature fluid (e.g., a heated exhaust gas stream),radiative heat transfer, use of thermoelectrics, microwave heating, andthe like. Different control algorithms based on a variety of possiblesensor inputs could be used to initiate the thermal activation. Variousforms of sensor inputs that could be used in deciding whether activationshould occur operation and status inputs for the load bearingstructure's given application. For instance, in the case of automotiveapplication, vehicle conditions such as speed, yaw rate, ABS operation,weather conditions, etc., prediction of an increasing probability of animminent loading event, for example, on input from a radar or visionbased object detection system, telematics, speed limit signs, and thelike), and finally, a signal from an on-board sensor that a loadingevent has started to occur. The amount of time that is available forthermo-molecular relaxation that underlies the change in modulus in theSMP decreases as the probability of such an event increases. Resistiveand pyrotechnic heating means, therefore, are two activation signalsthat can provide SMP activation times of 0.5 seconds or less.

For tunably compliant load bearing structures based on thermalactivation signals, such as may be the case with SMP, maintaining thepreconditioning temperature below the transformation temperature maycomprise providing a secondary activation signal at a level below thatwhich would normally cause transformation of the SMP. In this manner, aprimary activation signal can then be provided to effect deformation,wherein the primary signal would require minimal energy and time. In analternative embodiment, the environment in which the tunable bracket isdisposed can be maintained at a temperature below the transformationtemperature. In either embodiment, preconditioning can comprise atemperature sensor and a controller in operative communication with thetunably complaint load bearing structure. A feedback loop may beprovided to an activation device so as to provide the secondaryactivation signal if so configured. Otherwise, the temperature sensorand activation device can precondition the environment to minimize thetime to transition the SMP to its transformation temperature by means ofthe primary activation signal. The preconditioning may be static ortransient depending on the desired configuration.

The preconditioning temperature can be greater than about 50 percent ofthe temperature difference between the ambient temperature and the(lowest) glass transition temperature, with greater than about 80percent preferred, with greater than about 90 percent more preferred,and with greater than about 95 percent even more preferred.

The activation device can be programmed to cause activation of theactive material portion defining the tunable impedance load bearingstructure within the desired times suitable for the intendedapplication. For example, the activation device can be programmed toprovide either a high current or a low current to a resistive heatingelement in thermal communication with the active material, e.g., a SMP.The high current could be used to provide rapid irreversible activationwhereas the low current could be used to provide delayed reversibleactivation. The use of the high and low current in the manner describedis exemplary and is not intended to limit the programming varietyavailable for the activation device or to define the conditions forreversibility.

Sensor inputs can be varied in nature and number (pressure sensors,position sensors (capacitance, ultrasonic, radar, camera, etc.),displacement sensors, velocity sensors, accelerometers, etc.) and belocated on the support substrate, e.g., a vehicle body.

As previously described, suitable active materials for tunable impedanceload bearing structures include, without limitation, shape memory alloys(“SMAs”; e.g., thermal and stress activated shape memory alloys andmagnetic shape memory alloys (MSMA)), electroactive polymers (EAPs) suchas dielectric elastomers, ionic polymer metal composites (IPMC),piezoelectric materials (e.g., polymers, ceramics), and shape memorypolymers (SMPs), shape memory ceramics (SMCs), baroplastics,magnetorheological (MR) materials (e.g., fluids and elastomers),electrorheological (ER) materials (e.g., fluids, and elastomers),composites of the foregoing active materials with non-active materials,systems comprising at least one of the foregoing active materials, andcombinations comprising at least one of the foregoing active materials.For convenience and by way of example, reference herein will be made toshape memory alloys and shape memory polymers. The shape memoryceramics, baroplastics, and the like, can be employed in a similarmanner. For example, with baroplastic materials, a pressure inducedmixing of nanophase domains of high and low glass transition temperature(Tg) components effects the shape change. Baroplastics can be processedat relatively tow temperatures repeatedly without degradation. SMCs aresimilar to SMAs but can tolerate much higher operating temperatures thancan other shape-memory materials. An example of an SMC is apiezoelectric material.

The ability of shape memory materials to return to their original shapeupon the application or removal of external stimuli has led to their usein actuators to apply force resulting in desired motion. Active materialactuators offer the potential for a reduction in actuator size, weight,volume, cost, noise and an increase in robustness in comparison withtraditional electromechanical and hydraulic means of actuation.Ferromagnetic SMA's, for example, exhibit rapid dimensional changes ofup to several percent in response to (and proportional to the strengthof) an applied magnetic field. However, these changes are one-waychanges and use the application of either a biasing force or a fieldreversal to return the ferromagnetic SMA to its starting configuration.

Shape memory alloys are alloy compositions with at least two differenttemperature-dependent phases or polarity. The most commonly utilized ofthese phases are the so-called martensite and austenite phases. In thefollowing discussion, the martensite phase generally refers to the moredeformable, lower temperature phase whereas the austenite phasegenerally refers to the more rigid, higher temperature phase. When theshape memory alloy is in the martensite phase and is heated, it beginsto change into the austenite phase. The temperature at which thisphenomenon starts is often referred to as austenite start temperature(As). The temperature at which this phenomenon is complete is oftencalled the austenite finish temperature (Af). When the shape memoryalloy is in the austenite phase and is cooled, it begins to change intothe martensite phase, and the temperature at which this phenomenonstarts is often referred to as the martensite start temperature (Ms).The temperature at which austenite finishes transforming to martensiteis often called the martensite finish temperature (Mf). The rangebetween As and Af is often referred to as the martensite-to-austenitetransformation temperature range while that between Ms and Mf is oftencalled the austenite-to-martensite transformation temperature range. Itshould be noted that the above-mentioned transition temperatures arefunctions of the stress experienced by the SMA sample. Generally, thesetemperatures increase with increasing stress. In view of the foregoingproperties, deformation of the shape memory alloy is preferably at orbelow the austenite start temperature (at or below As). Subsequentheating above the austenite start temperature causes the deformed shapememory material sample to begin to revert back to its original(nonstressed) permanent shape until completion at the austenite finishtemperature. Thus, a suitable activation input or signal for use withshape memory alloys is a thermal activation signal having a magnitudethat is sufficient to cause transformations between the martensite andaustenite phases.

The temperature at which the shape memory alloy remembers its hightemperature form (i.e., its original, nonstressed shape) when heated canbe adjusted by slight changes in the composition of the alloy andthrough thermo-mechanical processing. In nickel-titanium shape memoryalloys, for example, it can be changed from above about 100° C. to belowabout −100° C. The shape recovery process can occur over a range of justa few degrees or exhibit a more gradual recovery over a widertemperature range. The start or finish of the transformation can becontrolled to within several degrees depending on the desiredapplication and alloy composition. The mechanical properties of theshape memory alloy vary greatly over the temperature range spanningtheir transformation, typically providing shape memory effect andsuperelastic effect. For example, in the martensite phase a lowerelastic modulus than in the austenite phase is observed. Shape memoryalloys in the martensite phase can undergo large deformations byrealigning the crystal structure arrangement with the applied stress.The material will retain this shape after the stress is removed. Inother words, stress induced phase changes in SMA are two

way by nature, application of sufficient stress when an SMA is in itsaustenitic phase will cause it to change to its lower modulusMartensitic phase. Removal of the applied stress will cause the SMA toswitch back to its Austenitic phase, and in so doing, recovering itsstarting shape and higher modulus.

Exemplary shape memory alloy materials include nickel-titanium basedalloys, indium-titanium based alloys, nickel-aluminum based alloys,nickel-gallium based alloys, copper based alloys (e.g., copper-zincalloys, copper-aluminum alloys, copper-gold, and copper-tin alloys),gold-cadmium based alloys, silver-cadmium based alloys, indium-cadmiumbased alloys, manganese-copper based alloys, iron-platinum based alloys,iron-palladium based alloys, and so forth. The alloys can be binary,temary, or any higher order so long as the alloy composition exhibits ashape memory effect, e.g., change in shape, orientation, yield strength,flexural modulus, damping capacity, superelasticity, and/or similarproperties. Selection of a suitable shape memory alloy compositiondepends, in part, on the temperature range of the intended application.

The recovery to the austenite phase at a higher temperature isaccompanied by very large (compared to that needed to deform thematerial) stresses which can be as high as the inherent yield strengthof the austenite material, sometimes up to three or more times that ofthe deformed martensite phase. For applications that require a largenumber of operating cycles, a strain of less than or equal to 4% or soof the deformed length of wire used can be obtained. This limit in theobtainable strain places significant constraints in the application ofSMA actuators where space is limited. MSMAs are alloys; often composedof Ni—Mn—Ga, that change shape due to strain induced by a magneticfield. MSMAs have internal variants with different magnetic andcrystallographic orientations. In a magnetic field, the proportions ofthese variants change, resulting in an overall shape change of thematerial. An MSMA actuator generally requires that the MSMA material beplaced between coils of an electromagnet. Electric current runningthrough the coil induces a magnetic field through the MSMA material,causing a change in shape.

As previously mentioned, other exemplary shape memory materials areshape memory polymers (SMPs). “Shape memory polymer” generally refers toa polymeric material, which exhibits a change in a property, such as amodulus, a dimension, a coefficient of thermal expansion, thepermeability to moisture, an optical property (e.g., transmissivity), ora combination comprising at least one of the foregoing properties incombination with a change in its a microstructure and/or morphology uponapplication of an activation signal. Shape memory polymers can bethermoresponsive (i.e., the change in the property is caused by athermal activation signal delivered either directly via heat supply orremoval, or indirectly via a vibration of a frequency that isappropriate to excite high amplitude vibrations at the molecular levelwhich lead to internal generation of heat), photoresponsive (i.e., thechange in the property is caused by an electromagnetic radiationactivation signal), moisture-responsive (i.e., the change in theproperty is caused by a liquid activation signal such as humidity, watervapor, or water), chemo-responsive (i.e. responsive to a change in theconcentration of one or more chemical species in its environment; e.g.,the concentration of H+ ion—the pH of the environment), or a combinationcomprising at least one of the foregoing.

Generally, SMPs are phase segregated co-polymers comprising at least twodifferent units, which can be described as defining different segmentswithin the SMP, each segment contributing differently to the overallproperties of the SMP. As used herein, the term “segment” refers to ablock, graft, or sequence of the same or similar monomer or oligomerunits, which are copolymerized to form the SMP. Each segment can be(semi-)crystalline or amorphous and will have a corresponding meltingpoint or glass transition temperature (Tg), respectively. The term“thermal transition temperature” is used herein for convenience togenerically refer to either a Tg or a melting point depending on whetherthe segment is an amorphous segment or a crystalline segment. For SMPscomprising (n) segments, the SMP is said to have a hard segment and(n-1) soft segments, wherein the hard segment has a higher thermaltransition temperature than any soft segment. Thus, the SMP has (n)thermal transition temperatures. The thermal transition temperature ofthe hard segment is termed the “last transition temperature”, and thelowest thermal transition temperature of the so-called “softest” segmentis termed the “first transition temperature”. It is important to notethat if the SMP has multiple segments characterized by the same thermaltransition temperature, which is also the last transition temperature,then the SMP is said to have multiple hard segments.

When the SMP is heated above the last transition temperature, the SMPmaterial can be imparted a permanent shape. A permanent shape for theSMP can be set or memorized by subsequently cooling the SMP below thattemperature. As used herein, the terms “original shape”, “previouslydefined shape”, “predetermined shape”, and “permanent shape” aresynonymous and are intended to be used interchangeably. A temporaryshape can be set by heating the material to a temperature higher than athermal transition temperature of any soft segment yet below the lasttransition temperature, applying an external stress or load to deformthe SMP, and then cooling below the particular thermal transitiontemperature of the soft segment while maintaining the deforming externalstress or load.

The permanent shape can be recovered by heating the material, with thestress or load removed, above the particular thermal transitiontemperature of the soft segment yet below the last transitiontemperature. Thus, it should be clear that by combining multiple softsegments it is possible to demonstrate multiple temporary shapes andwith multiple hard segments it can be possible to demonstrate multiplepermanent shapes. Similarly using a layered or composite approach, acombination of multiple SMPs will demonstrate transitions betweenmultiple temporary and permanent shapes.

The shape memory material may also comprise a piezoelectric material.Also, in certain embodiments, the piezoelectric material can beconfigured as an actuator for providing rapid deployment. As usedherein, the term “piezoelectric” is used to describe a material thatmechanically deforms (changes shape) when a voltage potential isapplied, or conversely, generates an electrical charge when mechanicallydeformed. Piezoelectrics exhibit a small change in dimensions whensubjected to the applied voltage, with the response being proportionalto the strength of the applied field and being quite fast (capable ofeasily reaching the thousand hertz range). Because their dimensionalchange is small (e.g., less than 0.1%), to dramatically increase themagnitude of dimensional change they are usually used in the form ofpiezo ceramic unimorph and bi-morph flat patch actuators which areconstructed so as to bow into a concave or convex shape upon applicationof a relatively small voltage. The morphing/bowing of such patcheswithin the liner of the holder is suitable for grasping/releasing theobject held.

One type of unimorph is a structure composed of a single piezoelectricelement externally bonded to a flexible metal foil or strip, which isstimulated by the piezoelectric element when activated with a changingvoltage and results in an axial buckling or deflection as it opposes themovement of the piezoelectric element. The actuator movement for aunimorph can be by contraction or expansion. Unimorphs can exhibit astrain of as high as about 10%, but generally can only sustain low loadsrelative to the overall dimensions of the unimorph structure.

In contrast to the unimorph piezoelectric device, a bimorph deviceincludes an intermediate flexible metal foil sandwiched between twopiezoelectric elements. Bimorphs exhibit more displacement thanunimorphs because under the applied voltage one ceramic element willcontract while the other expands. Bimorphs can exhibit strains up toabout 20%, but similar to unimorphs, generally cannot sustain high loadsrelative to the overall dimensions of the unimorph structure.

Exemplary piezoelectric materials include inorganic compounds, organiccompounds, and metals. With regard to organic materials, all of thepolymeric materials with noncentrosymmetric structure and large dipolemoment group(s) on the main chain or on the side-chain, or on bothchains within the molecules, can be used as candidates for thepiezoelectric film. Examples of polymers include poly(sodium4-styrenesulfonate) (“PSS”), poly S-119 (Poly(vinylamine) backbone azochromophore), and their derivatives; polyfluorocarbines, includingpolyvinylidene fluoride (“PVDF”), its co-polymer vinylidene fluoride(“VDF”), trifluorethylene (TrFE), and their derivatives;polychlorocarbons, including poly(vinylchloride) (“PVC”), polyvinylidenechloride (“PVC2”), and their derivatives; polyacrylonitriles (“PAN”),and their derivatives; polycarboxylic acids, including poly (methacrylicacid (“PMA”), and their derivatives; polyureas, and their derivatives;polyurethanes (“PUE”), and their derivatives; bio-polymer molecules suchas poly-L-lactic acids and their derivatives, and membrane proteins, aswell as phosphate bio-molecules; polyanilines and their derivatives, andall of the derivatives of tetraamines; polyimides, including Kapton®molecules and polyetherimide (“PEI”), and their derivatives; all of themembrane polymers; poly (N-vinyl pyrrolidone) (“PVP”) homopolymer, andits derivatives, and random PVP-co-vinyl acetate (“PVAc”) copolymers;and all of the aromatic polymers with dipole moment groups in themain-chain or side-chains, or in both the main-chain and theside-chains; as well as combinations comprising at least one of theforegoing.

Further, piezoelectric materials can include Pt, Pd, Ni, T, Cr, Fe, Ag,Au, Cu, and metal alloys comprising at least one of the foregoing, aswell as combinations comprising at least one of the foregoing. Thesepiezoelectric materials can also include, for example, metal oxide suchas SiO2, Al2O3, ZrO2, TiO2, SrTiO3, PbTiO3, BaTiO3, FeO3, Fe3O4, ZnO,and combinations comprising at least one of the foregoing; and Group VIAand IIB compounds, such as CdSe, CdS, GaAs, AgCaSe2, ZnSe, GaP, InP,ZnS, and combinations comprising at least one of the foregoing.

MR fluids is a class of smart materials whose rheological properties canrapidly change upon application of a magnetic field (e.g., propertychanges of several hundred percent can be effected within a couple ofmilliseconds), making them quite suitable in locking in (constraining)or allowing the relaxation of shapes/deformations through a significantchange in their shear strength, such changes being usefully employedwith grasping and release of objects in embodiments described herein.Exemplary shape memory materials also comprise magnetorheological (MR)and ER polymers. MR polymers are suspensions of micrometer-sized,magnetically polarizable particles (e.g., ferromagnetic or paramagneticparticles as described below) in a polymer (e.g., a thermoset elasticpolymer or rubber). Exemplary polymer matrices includepoly-alpha-olefins, natural rubber, silicone, polybutadiene,polyethylene, polyisoprene, and combinations comprising at least one ofthe foregoing.

The stiffness and potentially the shape of the polymer structure areattained by changing the shear and compression/tension moduli by varyingthe strength of the applied magnetic field. The MR polymers typicallydevelop their structure when exposed to a magnetic field in as little asa few milliseconds, with the stiffness and shape changes beingproportional to the strength of the applied field. Discontinuing theexposure of the MR polymers to the magnetic field reverses the processand the elastomer returns to its lower modulus state. Packaging of thefield generating coils, however, creates challenges.

MR fluids exhibit a shear strength which is proportional to themagnitude of an applied magnetic field, wherein property changes ofseveral hundred percent can be effected within a couple of milliseconds.Although these materials also face the issues packaging of the coilsnecessary to generate the applied field, they can be used as a lockingor release mechanism, for example, for spring based grasping/releasing.

Suitable MR fluid materials include ferromagnetic or paramagneticparticles dispersed in a carrier, e.g., in an amount of about 5.0 volumepercent (vol %) to about 50 vol % based upon a total volume of MRcomposition. Suitable particles include iron; iron oxides (includingFe2O3 and Fe3O4); iron nitride; iron carbide; carbonyl iron; nickel;cobalt; chromium dioxide; and combinations comprising at least one ofthe foregoing; e.g., nickel alloys; cobalt alloys; iron alloys such asstainless steel, silicon steel, as well as others including aluminum,silicon, cobalt, nickel, vanadium, molybdenum, chromium, tungsten,manganese and/or copper.

The particle size should be selected so that the particles exhibitmultiple magnetic domain characteristics when subjected to a magneticfield. Particle diameters (e.g., as measured along a major axis of theparticle) can be less than or equal to about 1,000 micrometers (μm)(e.g., about 0.1 micrometer to about 1,000 micrometers), or, morespecifically, about 0.5 to about 500 micrometers, and more specifically,about 10 to about 100 micrometers.

The viscosity of the carrier can be less than or equal to about 100,000centipoise (cPs) (e.g., about 1 cPs to about 100,000 cPs), or, morespecifically, about 250 cPs to about 10,000 cPs, or, even morespecifically, about 500 cPs to about 1,000 centipoise. Possible carriers(e.g., carrier fluids) include organic liquids, especially non-polarorganic liquids. Examples include oils (e.g., silicon oils, mineraloils, paraffin oils, white oils, hydraulic oils, transformer oils, andsynthetic hydrocarbon oils (e.g., unsaturated and/or saturated));halogenated organic liquids (such as chlorinated hydrocarbons,halogenated paraffins, perfluorinated polyethers and fluorinatedhydrocarbons); diesters; polyoxyalkylenes; silicones (e.g., fluorinatedsilicones); cyanoalkyl siloxanes; glycols; and combinations comprisingat least one of the foregoing carriers.

Aqueous carriers can also be used, especially those comprisinghydrophilic mineral clays such as bentonite or hectorite. The aqueouscarrier can comprise water or water comprising a polar, water-miscibleorganic solvent (e.g., methanol, ethanol, propanol, dimethyl sulfoxide,dimethyl formamide, ethylene carbonate, propylene carbonate, acetone,tetrahydrofuran, diethyl ether, ethylene glycol, propylene glycol, andthe like), as well as combinations comprising at least one of theforegoing carriers. The amount of polar organic solvent in the carriercan be less than or equal to about 5.0 vol % (e.g., about 0.1 vol % toabout 5.0 vol %), based upon a total volume of the MR fluid, or, morespecifically, about 1.0 vol % to about 3.0%. The pH of the aqueouscarrier can be less than or equal to about 13 (e.g., about 5.0 to about13), or, more specifically, about 8.0 to about 9.0.

When the aqueous carriers comprises natural and/or synthetic bentoniteand/or hectorite, the amount of clay (bentonite and/or hectorite) in theMR fluid can be less than or equal to about 10 percent by weight (wt %)based upon a total weight of the MR fluid, or, more specifically, about0.1 wt % to about 8.0 wt %, or, more specifically, about 1.0 wt % toabout 6.0 wt %, or, even more specifically, about 2.0 wt % to about 6.0wt %.

Optional components in the MR fluid include clays (e.g., organoclays),carboxylate soaps, dispersants, corrosion inhibitors, lubricants,anti-wear additives, antioxidants, thixotropic agents, and/or suspensionagents. Carboxylate soaps include ferrous oleate, ferrous naphthenate,ferrous stearate, aluminum di- and tri-stearate, lithium stearate,calcium stearate, zinc stearate, and/or sodium stearate; surfactants(such as sulfonates, phosphate esters, stearic acid, glycerolmonooleate, sorbitan sesquioleate, laurates, fatty acids, fattyalcohols, fluoroaliphatic polymeric esters); and coupling agents (suchas titanate, aluminate, and zirconate); as well as combinationscomprising at least one of the foregoing. Polyalkylene diols, such aspolyethylene glycol, and partially esterified polyols can also beincluded.

Electrorheological fluids (ER) fluids are similar to MR fluids in thatthey exhibit a change in shear strength when subjected to an appliedfield, in this case a voltage rather than a magnetic field. Response isquick and proportional to the strength of the applied field. It is,however, an order of magnitude less than that of MR fluids and severalthousand volts are typically required.

Electronic electroactive polymers (EAPs) are a laminate of a pair ofelectrodes with an intermediate layer of low elastic modulus dielectricmaterial. Applying a potential between the electrodes squeezes theintermediate layer causing it to expand in plane. They exhibit aresponse proportional to the applied field and can be actuated at highfrequencies. EAP morphing laminate sheets have been demonstrated. Theirmajor downside is that they require applied voltages approximately threeorders of magnitude greater than those required by piezoelectrics

Electroactive polymers include those polymeric materials that exhibitpiezoelectric, pyroelectric, or electrostrictive properties in responseto electrical or mechanical fields. An example of anelectrostrictive-grafted elastomer with a piezoelectric poly(vinylidenefluoride-trifluoro-ethylene) copolymer. This combination has the abilityto produce a varied amount of ferroelectric-electrostrictive molecularcomposite systems.

Materials suitable for use as an electroactive polymer may include anysubstantially insulating polymer and/or rubber that deforms in responseto an electrostatic force or whose deformation results in a change inelectric field. Exemplary materials suitable for use as a pre-strainedpolymer include silicone elastomers, acrylic elastomers, polyurethanes,thermoplastic elastomers, copolymers comprising PVDF, pressure-sensitiveadhesives, fluoroelastomers, polymers comprising silicone and acrylicmoieties (e.g., copolymers comprising silicone and acrylic moieties,polymer blends comprising a silicone elastomer and an acrylic elastomer,and so forth).

Materials used as an electroactive polymer can be selected based onmaterial properties such as a high electrical breakdown strength, a lowmodulus of elasticity (e.g., for large or small deformations), a highdielectric constant, and so forth. In one embodiment, the polymer can beselected such that is has an elastic modulus of less than or equal toabout 100 MPa. In another embodiment, the polymer can be selected suchthat is has a maximum actuation pressure of about 0.05 megaPascals (MPa)and about 10 MPa, or, more specifically, about 0.3 MPa to about 3 MPa.In another embodiment, the polymer can be selected such that is has adielectric constant of about 2 and about 20, or, more specifically,about 2.5 and about 12. The present disclosure is not intended to belimited to these ranges. Ideally, materials with a higher dielectricconstant than the ranges given above would be desirable if the materialshad both a high dielectric constant and a high dielectric strength. Inmany cases, electroactive polymers can be fabricated and implemented asthin films, e.g., having a thickness of less than or equal to about 50micrometers.

As electroactive polymers may deflect at high strains, electrodesattached to the polymers should also deflect without compromisingmechanical or electrical performance. Generally, electrodes suitable foruse can be of any shape and material provided that they are able tosupply a suitable voltage to, or receive a suitable voltage from, anelectroactive polymer. The voltage can be either constant or varyingover time. In one embodiment, the electrodes adhere to a surface of thepolymer. Electrodes adhering to the polymer can be compliant and conformto the changing shape of the polymer. The electrodes can be only appliedto a portion of an electroactive polymer and define an active areaaccording to their geometry. Various types of electrodes includestructured electrodes comprising metal traces and charge distributionlayers, textured electrodes comprising varying out of plane dimensions,conductive greases (such as carbon greases and silver greases),colloidal suspensions, high aspect ratio conductive materials (such ascarbon fibrils and carbon nanotubes, and mixtures of ionicallyconductive materials), as well as combinations comprising at least oneof the foregoing.

Exemplary electrode materials can include graphite, carbon black,colloidal suspensions, metals (including silver and gold), filled gelsand polymers (e.g., silver filled and carbon filled gels and polymers),and ionically or electronically conductive polymers, as well ascombinations comprising at least one of the foregoing. It is understoodthat certain electrode materials may work well with particular polymersand may not work as well for others. By way of example, carbon fibrilswork well with acrylic elastomer polymers while not as well withsilicone polymers.

Magnetostrictives are solids that develop a large mechanical deformationwhen subjected to an external magnetic field. This magnetostrictionphenomenon is attributed to the rotations of small magnetic domains inthe materials, which are randomly oriented when the material is notexposed to a magnetic field. The shape change is largest inferromagnetic or ferromagnetic solids. These materials possess a veryfast response capability, with the strain proportional to the strengthof the applied magnetic field, and they return to their startingdimension upon removal of the field. However, these materials havemaximum strains of about 0.1 to about 0.2 percent.

Advantageously, the above disclosed tunable impedance load bearingstructures can permanently or reversibly produce a compliancecharacteristic change on demand, in response to external stimulus,activation signals generated in response to conditions measured bysensors, or environmental changes, by employing active materials. Theactive material based load bearing structures can provide largedeformations without a significant amount of external loading and limitdeflections under significant loads, thereby providing a tuned responsedepending on existing circumstances and/or preferences. Because of theunique properties of the active materials, all of the above disclosedimpedance tuning methods can be implemented and/or controlled while theload bearing structure is in use.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to make and use the invention. The patentable scope of the inventionis defined by the claims, and may include other examples that occur tothose skilled in the art. Such other examples are intended to be withinthe scope of the claims if they have structural elements that do notdiffer from the literal language of the claims, or if they includeequivalent structural elements with insubstantial differences from theliteral languages of the claims.

1. A tunable impedance load bearing structure, comprising: a supportcomprising an active material configured for supporting a load, whereinthe active material undergoes a change in a property upon exposure to anactivating condition, wherein the change in the property is effective tochange an impedance characteristic of the support.
 2. The tunableimpedance load bearing structure of claim 1, wherein the active materialcomprises a shape memory polymer, a shape memory alloy, a ferromagneticshape memory alloy, an electroactive polymer, a piezoelectric material,a magnetorheological elastomer, an electrorheological elastomer, orcombinations comprising at least one of the foregoing active materials.3. The tunable impedance load bearing structure of claim 1, wherein thechange in a property comprises a change in an elastic modulus, a shape,a dimension, a shape orientation, a component location, a phase change,or combinations comprising at least one of the foregoing properties. 4.The tunably compliant load bearing structure of claim 1, wherein thechange in an impedance characteristic comprises a change in a stiffness,a damping capability, a yield strength, a shear strength, aforce-deflection behavior, a preferred mode of deformation, aload-carrying capacity, a load path within the structure, an energyabsorption capacity, or combinations comprising at least one of theforegoing characteristics.
 5. The tunable impedance load bearingstructure of claim 1, further comprising an activation device inoperative communication with the active material, to provide theactivating condition to the active material, wherein the activatingcondition comprises a thermal activation signal, an electric activationsignal, a magnetic activation signal, a chemical activation signal, amechanical signal, or a combination comprising at least one of theforegoing activation signals.
 6. The tunable impedance load bearingstructure of claim 1, wherein the support further comprises a firstportion, a second portion, and a third portion, wherein the secondportion comprises the active material and is disposed between the firstportion and the second portion.
 7. The tunable impedance load bearingstructure of claim 1, wherein the support further comprises a flatportion having a first aperture in physical communication with anangular portion having a second aperture coaxially aligned with thefirst aperture, and a pin disposed in the first and the secondapertures, wherein the active material is adapted to actuate the pin. 8.The tunable impedance load bearing structure of claim 7, wherein the pincomprises the active material.
 9. A tunable impedance load bearingstructure, comprising: a support configured for supporting a load,comprising. an upper portion having a first flat surface and a secondflat surface, wherein a canted beam element is disposed between thefirst flat surface and the second flat surface; a first disc comprisingan active material in physical communication with the second flatsurface of the upper portion, wherein the active material undergoes achange in a property upon exposure to an activating condition, whereinthe change in the property is effective to change a compliancecharacteristic of the support; and a second disc in physicalcommunication with the first disc.
 10. The tunable impedance loadbearing structure of claim 9 wherein the active material comprises ashape memory polymer, a shape memory alloy, a ferromagnetic shape memoryalloy, an electroactive polymer, a piezoelectric material, amagnetorheological elastomer, an electrorheological elastomer, orcombinations comprising at least one of the foregoing active materials.11. The tunable impedance load bearing structure of claim 9, wherein thechange in a property comprises a change in an elastic modulus, a shape,a dimension, a shape orientation, a component location, a phase change,or combinations comprising at least one of the foregoing properties. 12.The tunable impedance load bearing structure of claim 9, wherein thechange in a compliance characteristic comprises a change in a stiffness,a damping capability, a yield strength, a shear strength, aforce-deflection behavior, a load-carrying capacity, an energyabsorption capacity, or combinations comprising at least one of theforegoing characteristics.
 13. The tunable impedance load bearingstructure of claim 9, further comprising an activation device inoperative communication with the active material, to provide theactivating condition to the active material, wherein the activatingcondition comprises a thermal activation signal, an electric activationsignal, a magnetic activation signal, a chemical activation signal, amechanical signal, or a combination comprising at least one of theforegoing activation signals.
 14. A method for changing an impedancecharacteristic of a load bearing structure, the method comprising:disposing a load bearing structure intermediate a substrate and a load,wherein the load bearing structure comprises a support configured forsupporting the load, wherein the support comprises an active material;and activating the active material to effect a change in a property ofthe active material, wherein the change in the property is effective tochange an impedance characteristic of the load bearing structure. 15.The method of claim 14, wherein the active material comprises a shapememory polymer, a shape memory alloy, a ferromagnetic shape memoryalloy, an electroactive polymer, a piezoelectric material, orcombinations comprising at least one of the foregoing active materials.16. The method of claim 14, wherein the change in a property comprises achange in an elastic modulus, a shape, a dimension, a shape orientation,a component location, a phase change, or combinations comprising atleast one of the foregoing properties.
 17. The method of claim 14,wherein the change in an impedance characteristic comprises a change ina stiffness, a damping capability, a yield strength, a shear strength, aforce-deflection behavior, a load-carrying capacity, an energyabsorption capacity, or combinations comprising at least one of theforegoing characteristics.
 18. The method of claim 14, whereinactivating the active material is accomplished using an activationdevice in operative communication with the active material, wherein theactivation device is operable to selectively apply an activation signalto the active material.
 19. The method of claim 18, wherein theactivation signal comprises a thermal activation signal, an electricactivation signal, a magnetic activation signal, a chemical activationsignal, a mechanical signal, or a combination comprising at least one ofthe foregoing activation signals.
 20. The method of claim 14, whereinthe disposing the load bearing structure intermediate a substrate and aload further comprises activating the active material to position theload relative to the substrate, and deactivating the active material tomaintain the load in the position.